Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication, cooling system, fuel system (carbureted and fuel injected), exhaust system, timing components.
Engine Performance:
Engine tuning, diagnostics, emissions control, component testing.
Transmission Drivetrain:
Manual transmissions (A500, A500SE), Automatic transmissions (A500, A518, A618), transfer cases (for 4WD models), driveshafts, axles, differentials, wheel bearings.
Brakes:
Front disc brakes, rear drum brakes, parking brake system, hydraulic system, ABS (Anti-lock Braking System) for applicable models.
Steering Suspension:
Power steering system, steering column, steering gear, front suspension (independent torsion bar or coil spring), rear suspension (leaf spring), shock absorbers, control arms, sway bars.
Electrical System:
Battery, charging system (alternator), starting system, ignition system, lighting system (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, power distribution.
Body Chassis:
Body construction, chassis frame, doors, hood, tailgate, bumpers, interior trim, seating, glass, weatherstripping, frame alignment.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant service, blower motor, controls.
Fuel System:
Fuel tanks, fuel pump, fuel lines, fuel injectors, throttle body, evaporative emission control (EVAP) system.
Cruise Control:
Diagnosis and repair of the cruise control system, including actuators, control modules, and switches.
Instrument Panel:
Removal and repair of the instrument cluster, gauges, warning lights, and associated sensors.
Maintenance:
Scheduled maintenance procedures, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement.
Troubleshooting:
Diagnostic procedures for common symptoms, fault code interpretation, electrical circuit testing, mechanical component diagnosis.
Repair:
Step-by-step repair instructions for all major vehicle systems, component removal and installation, engine overhaul, transmission overhaul, brake system repairs, suspension component replacement.
Diagnostics:
Detailed diagnostic flowcharts, testing procedures for sensors and actuators, use of diagnostic tools.
Body Repair:
Includes procedures for body panel alignment, glass replacement, door and tailgate adjustments, and interior trim removal/installation.
Wheel Tire Service:
Information on wheel bearing replacement, tire rotation, and specifications for wheel alignment.
Wiring Diagrams:
Extensive, system-by-system wiring diagrams for all major electrical components, enabling precise troubleshooting of electrical faults.
Emission Controls:
Details on catalytic converters, EGR valves, O2 sensors, and the evaporative emission control system, including diagnostic and repair procedures.
Technical Depth:
Comprehensive from basic maintenance to advanced engine and transmission rebuilds. Includes detailed specifications, torque values, and wiring diagrams.
Diagnostic Tools Coverage:
Covers basic diagnostic tool usage, multimeter testing, and often references specific Chrysler diagnostic codes (e.g., OBDI) for the era.
Recommended Oil Change Interval:
Typically every 3,000 to 5,000 miles, or 6 months, depending on driving conditions and oil type. Check manual for specific recommendations.
Engine Oil Specification:
API Service SG/SH or higher. Viscosity typically 5W-30 or 10W-30 depending on climate (e.g., SAE 5W-30 for temperatures below 0°F, SAE 10W-30 for temperatures above 0°F).
Coolant Specification:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Check for Mopar specifications for the era (e.g., Mopar Antifreeze/Coolant).
Transmission Fluid Specification Automatic:
Chrysler ATF+3 (or equivalent) for A500/A518/A618 transmissions. Check manual for exact specification based on transmission model.
Transmission Fluid Specification Manual:
API GL-4 or GL-5 gear lubricant, typically SAE 75W-90 or SAE 80W-90 for manual transmissions. Refer to specific transmission type in manual.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Common Issues Electrical:
Corrosion in wiring harnesses, faulty grounds, intermittent gauge operation, issues with power windows/locks if equipped.
Common Issues Engine:
Head gasket leaks (especially on earlier 4-cylinders), exhaust manifold cracks, oil leaks from valve covers and oil pan gaskets, distributor issues, timing chain wear.
Common Issues Transmission:
Torque converter lock-up issues in automatics, worn synchros in manuals, potential leaks from seals and gaskets.
Common Issues Suspension:
Worn ball joints and tie rod ends, sagging leaf springs, worn control arm bushings.
Common Issues Chassis:
Frame rust (depending on climate/care), exhaust system corrosion.
Engine Oil Capacity:
Varies by engine: approx. 5 quarts (4.7L) for 4-cylinders, 5.5 quarts (5.2L) for V6 engines, 6 quarts (5.7L) for 5.2L V8. Always verify with dipstick.
Cooling System Capacity:
Approx. 12-14 quarts (11.4-13.3L) depending on engine and radiator size.
Transmission Fluid Capacity Automatic:
Approx. 3.5-4 quarts (3.3-3.8L) for A500, A518, A618 transmissions for a fluid change. Total capacity higher.
Fuel Tank Capacity:
Typically 20-23 gallons (75.7-87.1L) depending on cab and bed configuration.